Cast hinge and method of forming

ABSTRACT

Hinge formed by simultaneously casting separate pivotal elements. The hinge main body includes a pivot portion formed by a barrel at one end and projecting studs on one side for fastening to a swinging door or the like. A pivoting hinge tab is mounted within the barrel. In the closed position all fastening means are hidden from view, and the tab forms a substantially continuous surface with the outside of the hinge body. A two-step die casting process is used to form the hinge tab in pivoting relationship on the main body, and the pivot may be formed by a steel pin and surrounding bushing that is inserted in the forming die during the first step.

United States Patent 1191 Dobrjanskyj et al.

[i 3,868,746 [4 1 Mai.'4, 1975 1 CAST HINGE AND METHOD OF FORMING both of NY.

[73] Assignee: Coats & Clark, Inc., New York.

[22] Filed: May 15. 1972 211 Appl. No.1 252,996

[52] U.S. Cl. 16/128 [51] Int. Cl. EOSd U100 [58] Field of Search 16/128. 164. 170. 148.

[56] References Cited UNITED STATES PATENTS 1/1875 Selden 16/170 10/1913 McKinney.

8/1936 Maisch 16/148 5055 et al. 16/148 Primary Ewminer-Paitl R. Gilliam Assistant Examinee-Doris L. Troutman [57} ABSTRACT Hinge formed by simultaneously casting separate pivotal elements. The hinge main body includes a pivot portion formed by a barrel at one end and projecting studs on one side for fastening to a swinging door or the like. A pivoting hinge tab is mounted within the barrel. 1n the closed position all fastening means are hidden from view. and the tab forms a substantially continuous surface with the outside of the hinge body. A two-step die casting process is used to form the hinge tab in pivotingrelationship on the main body. and the pivot may be formed by a steel pin and surrounding bushing that is inserted in the forming die during the-first step.

l3Claims. 23 Drawing Figures PATENTED 41975 SHEET 3 OF 3 CAST HINGE AND METHOD OF FORMING BROAD STATEMENT OF INVENTION The present invention relates to a hinge and the method of its casting and is particularly concerned with the shape and location of the fastening means which is hidden in closed position.

DESCRIPTION OF THE PRIOR ART It is known in the prior art to form pivotal hinges, and it is also known that pivotal elements can be formed in a two-step process. An example of such process is shown in U.S. Pat. No. 2,819,494 issued on Jan. 14, 1958 to Louis H. Morin. In this known two-step casting a pivot was provided that would allow one element to be rotated with respect to the other. However, the usual type of hinge where elements pivot on each other includes a fastening means, such as screws, that pass through the separate portions so that such fastening means remain in view when the hinge is mounted. Moreover, such fastening means interfere with the visual effect if it is desired to put a design on the hinge surface. Additionally, the amount of play in the pivot of the prior art may not provide the desired control. Accordingly, it would be desired to provide a cast hinge wherein the fastening means are hidden from view in the closed position, a substantially continuous flat surface is provided by the hinge in the closed position, and the play in the pivot can be controlled during the formation thereof.

DESCRIPTION OF THE INVENTION The present invention provides a hinge wherein the body portion and connecting pivotal tab include fastening means hidden from view in the closed position.

In the present invention a hinge is provided wherein the hinge body includes a barrel portion on which a tab is pivoted so that in closed position the tab and hinge body form a substantially continuous outer surface.

A further provision of the present invention is a hinge wherein the fastening means for the hinge body and the fastening means for the pivotally mounted tab are visible only when the hinge is in the open position.

There is also provided by the present invention a hinge wherein the main body has an outer side that is substantially continuous and an inner side that includes projecting studs for fastening to a door or the like, and the hinge tab is pivotally mounted and includes leg portions for its fastening means that is hidden from view in the closed position.

There is further provided in the present invention a hinge having a hinge body including a notched section within which part of a pivotally mounted hinge tab has a flush relationship, and grooves are forced into the hinge body adjacent the notch to loosen the pivot mounting.

There is further provided a hinge having a pivotally 2 in which the pivot is provided by apair of projecting inserts between the hinge body and the tab, and the fastening means of the hinge are hidden from view in the closed position.

A still further provision of the present invention is a method of forming a hinge by a two-step casting process in which a bearing insert is mounted within the hinge body formed in the first step, and the connected pivotally mounted hinge tab is formed around the bearing in a manner so that in the closed position the fastening means is hidden from view. Another provision of the present invention is a method of forming a hinge wherein the fastening means for a pivotally connected hinge body and a hinge tab is hidden from view, and the pivot is provided in the first step of a two-step casting process by locating a pair of projecting elements to form the pivot points.

In a preferred embodiment of the invention a hinge is provided which includes a hinge: body and a pivotally connected hinge tab. The tab is fixedly mounted, such as by screws, to a base location, such as the frame of a door. The hinge body is then mounted, such as by screws, to a door or the like to be swingable on the base portion. The hinge body is formed as the first step of a two-step casting process, and one end of the hinge body is formed with spaced barrel sections on the inside of which projections are formed for the pivot. Extending along the hinge body on the inside surface are at least one pair of studs which can be tapped to receive mounting screws extending from the inside of the door. The outside surface of the hinge body is substantially continuous with the mounting means hidden from view. In the second step of the casting process the hinge tab is formed to pivot around the projections. The hinge body includes at its barrel end a notched section, and

in the closed position the hinge body receives a part of.

the hinge tab in a manner that is flush with the outer continuous surface. In this closed position the fastening means of the hinge tab are covered by the hinge body so that such fastening means are not visible, and the substantially continuous outer surface of the hinge body lends itself to the placement of a decorative design thereon The projections are: formed to taper inwardly to form a 30 angle so as to improve the pivot action. The pivot is further loosened by forming at least one groove extending from the notched area along the hinge body by forcing in a punch to spread the pivot projections. The hinge body has side flange portions extending from the barrel section partway along the hinge body to determine the location of the edge of the door or the like when the hinge body is mounted thereon.

Another embodiment of the present invention involves the use of an insert for improving the pivot ac tion. In the two-step casting process the hinge body is formed by afirst step in a first die mold, then the solidified body moves to a second die mold where the hinge tab is formed by a second step about the pivot. In the second embodiment an insert comprising a steel pin or shaft having a metal bushing rotatable therearound is placed in the first die mold so that the hinge body is formed therearound. Narrowed portions are formed in the steel pin adjacent its ends for better gripping by the cast body, and in the second die mold the hinge tab is formed around the bushing portion. The hinge may be formed of different materials. such as thermoplastic or metal, but is is preferred that the hinge be formed of a zinc alloy so that the steel pin with a bushing that can he steel or brass provides improved wear for the hinge.

A third embodiment of the invention involves the use of a pivot insert similar to the second embodiment except that the bushing is formed of thermoplastic material, such as nylon. In the second step of the process the zinc material of the hinge shrinks around the nylon exerting a pressure torque which may be desired in certain situations to provide less play for the pivot. The amount of pressure torque can be controlled by the thickness of the nylon bushing, and use of the nylon bushng will provide better wear and more quiet performance as well as a self-lubricating feature. Itis understood that with the use of the pin and bushing of the second and third embodiments that the formation of a loosening groove is unnecessary.

A further embodiment of the present invention involves the use of a pivoting insert formed by a pair of caps or separate tapered projections inserted in the die of the first step to form the pivot on the barrel portions of the hinge body. The tapered caps can be formed of brass, and they can be impregnated with graphite or other lubricants for improving the pivot action.

In all of the embodiments the final product produced by casting is plated, lacquered and lubricated for the final finishing steps.

In the above described embodiments the method of forming the hinge in two casting steps by providing an insert in the first die illustrates a novel forming of the pivot.

The nature of'the present invention will become more apparent and better understood from the following description and accompanying drawings in which:

FIG. 1 is an elevational view showing the hinge of the present invention incorporated on a door in closed position; I

FIG. 2 is a view similar to FIG. 1 with the hinge and door swung open 90;

FIG. 3 is a view similar to FIG. 1 with the hinge and door swung open 180;

FIG. 4 is a perspective view showing the top or outer surface of the hinge in closed position;

FIG. 5 is a perspective view showing the bottom or inside surface of the hinge in open position;

FIG. 6 is a plan view of the inside of the hinge in open position;

FIG. 7 is a side elevational view of the hinge in open position;

FIG. 8 is an end view of the hinge in open position;

FIG. 9 is a plan view of the inside of the hinge in closed position;

FIG. 10 is a side elevational view of the hinge in closed position;

FIG. 11 is an end view of the hinge in closed position;

FIG. 12 is a perspective view of the hinge body with part broken away to clearly show a pivot projection;

FIG. 13 is a topplan view of the hinge body with part broken away to clearly show the angle of the pivot projection;

. FIG. 14 is a perspective view of the hinge tab;

FIG. 15 is a schematic representation of a two-step casting process for forming the hinge of the present invention;

FIG. 16 is another embodiment of the present invention showing a sectional view of an insert forming the pivot of the hinge;

FIG. I7 is a further embodiment ofthe present invention showning another insert for forming the pivot of the hinge;

FIG. 18 is a schematic representation of the two-step casting process for forming the hinge using the inserts shown in FIG. 16 or in FIG. 17;

FIG. 19 is still another embodiment of the present invention showing the use ofa plurality of inserts to form the pivot of the hinge;

FIG. 20 is an enlarged perspective view of one of the inserts shown in FIG. 19;

FIG. 21 is a schematic representation of the two-step casting process for forming the hinge using the inserts shown in FIGS. 19 and 20;

FIG. 22 is a plan .view of the outside of the hinge of the present invention in closed position showing a design formed thereon; and

FIG. 23 is a view of the inside of the hinge of FIG. 22 in open position.

It will be understood that the accompanying-drawings are in part diagrammatic illustrations, and reference should be made to the followingdescription for a more detailed explanation of the present invention.

FIGS. I-3 illustrate the installation of the hinge of the present invention. As shown in these Figures. a cabinet door is used for the installation, but it is to be understood that the invention is not to be limited to the use of the hinge on a cabinet door, since the hinge could be used in many other installations where a swinging or pivotal movement is desired, such as a louvre door or the like. FIG. 1 illustrates the hinge in the closed position, and it is to be noted, as more clearly seen in FIG. 4, that the fastening means are not visible nor accessible when the hinge is closed. In the embodiment shown in FIGS. 1-3 a pair of spaced hinges 30 are mounted on cabinet door 32 which is closable on a fixed base or cabinet 34. A knob or pull 36 is mounted on door 32 on the side opposite to the hinges and utilized in a conventional manner for opening door 32. The knob 36 may include a lock which is particularly useful with hinge 30 for security reasons as will be explained hereinafter. Cabinet 36 may include shelves 38- for dishes, cups or the like although cabinet 36 could also be used for other purposes, such as a medicine cabinet; or door 32 could be used for other purposes wherever a door or similar swinging panel is desired.

In the embodiment shown in FIGS. l-3 hinges 30 of the present invention are illustrated in different positions, and in FIG. 2 door 32 has been swung open In the open position the elements of the hinge are visible, and as shown in FIGS. 4 and 5, hinge 30 comprises a main hinge body 40 that is attached to the swingable element, shown as door 32, and a hinge tab 42 that has one end pivotally mounted on hinge body 40, and the other end is fastened to the fixed base, shown as cabinet 34. In FIG. 2 with door 32 swung open it is seen that hinge tab 42 becomes visible.

Hinge body 40 comprises an outer side or surface 44 that is substantially smooth or continuous as shown in FIG. 4 and an inner side or surface 46 as shown in FIG.

5. Projecting inwardly from inner side 46 are a plurality of studs 48 with two studs being preferred as shown. It is an important feature of the invention that studs 48 are visible only on the inner side of the hinge, andare not visible when the hinge is closed as shown in FIG. 1. In order to mount hinge 30 on the swinging element or door 32, holes would be drilled through door 32 into which studs 48 would be inserted. As a step in forming and mounting the hinge, studs 48 would be internally tapped to form internal threads 50 so that fasteners such as screws could be inserted from the inside of door 32 into fastening engagement with threaded portions 50.

When door 32 is swung open l80as shown in FIG. 3, the fastening means for hinge body 40, such as screws 52, are then visible from the inside of door 32. In this open position of hinge and door 32 as shown in FIGS. 2 and 3, the fastening means for hinge tab 42 also are visible as will be explained hereinafter. 1

Referring to FIGS. 5-8, different views are shown of hinge 30 in thefully opened position which would correspond to FIG. 3. FIGS. 9-11 show hinge 30 in the closed position which would correspond to FIGS. 1 and 4. As shown in these views, hinge body is elongated with studs 48 spaced in alignment along a longitudinal center line of the body. However, it is to be understood that the hinge of the present invention need not have a main hinge body of elongated shape. The hinge body 40, for example, could have a square shape with the studs spaced transversely and equi-distant from the a fleur-de-lis pattern, then surface 72 has a corresponding design so it need not necessarily be flat, as long as it includes a corresponding design.

Hinge tab 42 includes a second part 76 that is located outwardly from first part 66 spaced from hinge body 40 in the opened position as shown in FIG. 5. Second part 76 is substantially rectangular in cross-section and can be considered to comprise leg sections 80 extending outwardly from adjacent the end of first part 66. As shown in FIG. 5, second part 76 comprises a surface 84 that abuts fixed base 34 and further includes an opposite surface 82. As seen in FIGS. 7l1, surface 84 is substantially flat and extends to form one side of part 76 and terminates in an inward step 88 that connects with circular portion 74.

An inclined surface 90 connects surface 72 of first part 66 with a central area of second part 76 (see FIGS. 5 and 9). Surface 90 is inclined with the angle as shown in FIG. 7 for the purpose of allowing swinging movement of hinge body 40 so that first part 66 substantially fills notched opening 70 as it is swunginto closed posiv tion.

hinge tab. The hinge body could also have a decorative design shape formed on surface 44, such as is shown in FIG. 22, or it could be designed with a fleur-de-lis of other configuration on surface 44. Alternatively. its shape could have the dimension extending away from the hinge tab less than the transverse dimension parallel to the hinge tab. The only requirement is that there be sufficient surface so-that at least two studs could be formed or cast on the inner side of the hinge body.

Hinge body 40 includes a pivot section at one end thereof, and at the outer ends of section 60 flanges 56 are formed to extend partway along hinge body 40 to terminate in edges 54. Upon installation, the end of door 32 aligns with edges 54, and studs 48 thereupon extend into corresponding openings in the door as explained above. Flanges 56 act as an enclosure for hinge tab 42 in the closed position (see FIG. 9) as well as determining the alignment with the edge of door 32. Pivot section 60 comprises barrel sections 62 extending inwardly toward each other along the one end of hinge body 40 and including end surfaces 64 that are substantially perpendicular to inner side 46 and spaced from each other to receive therebetween a first part 66 of hinge tab 42 in the pivotal mounting.

Barrel sections 62 are generally circular in shape on the inside of hinge body 40 and include a substantially flat surface 68 on the outside of hinge'body 40 so that outer side 44 and flat surface 68 form the substantially flush and continuous surface shown in FIG. 4.

A notched or cut-out section 70 extends inwardly from surfaces 64 into hinge body 40. In the open position of hinge 30 notched area 70 appears as an opening as most clearly shown in FIGS. 5 and 6, and thepart 66 of hinge tab 42 is so configured that it completely fills opening 70 when the hinge is in the closed position as shown in FIGS. 1 and 4 so that the substantially flush and continuous outer surface 44 is maintained. In this respect it is to be noted that first part 66 includes a flat I surface 72 that forms the flush extension of outer surface 44 in the closed position of the hinge. First part 66 includes a generally circular surface 74 that is alignable with and matches circular barrel sections 62 when the hinge is in the closed position. It is to be understood that if surface 44 has a specific design thereon. such as Legs of second part 76 have openings 92 formed therethrough for the purpose of receiving fastening means (see FIG. 14). That part of surface 82 where openings 92 terminate have counter-sunk openings 94 for receiving the heads of fasteners such as screws 52 when hinge tab 42 is mounted on the base element such as cabinet 34.

The pivot mounting between hinge body 40 and hinge tab 42 is formed in a two-step casting process as will be explained hereinafter. In the formation of the pivotal mounting at area 60, it may be desired to provide additional freedom or play in the pivot mounting. As shown in FIGS. 12 14 the pivot is provided by forming projections on barrel portions 62 of hinge body 40 and subsequently casting hinge tab 42 therearound. In order to provide the desired play of the pivot, a clearance is formed between the projections and corre* sponding receiving depressions in the hinge tab as will now be explained. FIG. 15 is a schematic representation of the casting apparatus for forming the hinge of the'present invention, and the dotted outline represents one side of a pair of movable dies within which the hinge is formed in a two-step casting process, the general concept of which is explained in the aforemen tioned US. Pat. No. 2,819,494. A transfer core 102 is provided for moving the hinge body that is first formed between an upper set of die molds to a lower position where the hinge tab is formed in the second step of the casting. It is to be understood that one hinge body 40 and one hinge tab 42 are formed sumultaneously as the heated material, which may be plastic or metal, flows into gate 104, around transfer core 102 and into gates 106 and 108 from which a branch gate 110 allows the heated material to flow onto the lower die molds to form hinge tab 42. It is further understood that a previously formed hinge body has moved from the upper molds following the first step of the process to the lower molds where it is designated 40' and is in solidified condition when the hinge tab 42 is formed. The upper die molds include tapered depressions (not shown) so that corresponding tapered projections1l2 are formed to extend inwardly from surfaces 64 of barrel sections 62 (see FIGS. 12 and 13). As shown in FIG. 15, projections 112 are spaced from each other and act as pivotpoints when hinge tab 42 is formed therearound. Projections 112 are tapered inwardly and terminate in a flat surface 114 so that they have the shape of a truncated cone with the outer opposing surface of the cone forming a 30 degree angle as shown in FIG. 13. In the lower position of die 100 the flow of the molten material through gate 110 forms hinge tab 42 with corresponding tapered depressions 116 (see FIG. 14) as the metal flows around projections 112. The shrinkage of the molten material, such as a zinc alloy, upon the solidified metal allows a clearance to be formed betweendepression 116 and projection 112 so that a hinged or pivotal relationship is thereby provided between hinge body 40 and hinge tab 42. This basic concept of forming pivotal elements is shown and described in the aforementioned patent, and the pivotal play provided may be sufficient for certain usages. However, if additional play or clearance is desired between projection 112 and depression 116, loosening means such as a pair of spreading grooves 120 can be formed in. inner surface 46 adjacent to and extending from the opening 70. It is possible to provide the same loosening or additional clearance by use ofa single centrally located spreading groove 122 as shown in FIG. 12 which more clearly shows the angular shape of the groove. This increase in clearance is known as staking and can be provided as a third step in the casting process when a punch (not shown) having the curved or angular surface is forced into inner surface 46 while it is still hot causing an outward spreading of the barrel sections 62 and an increased clearance between projections 112 and depressions 116.

As mentioned hereinabove, it may not be necessary to increase the clearance and play of the pivot, but if increased play is desired, the previously described staking step is merely one possibility for increasing the play of the pivot. Additional procedures for changing the pivot action will now be described.

FIGS. 16 and 17 illustrate two embodiments whereby an improved pivot action in the hinge isprovided by a pre-assembled insert placed in the die prior to the formation of the hinge bodyin the first step of the casting process. FIG. 16' illustrates a pre-assembly 120 provided by a steel pin or shaft 122 on which is rotatably mounted a metal bushing 124. As mentioned previously, hinge 30 can be formed ofeither plastic or metal, but the preferred material is a'zinc alloy. By the use of preassembly 1 20 better wear surface and predetermined clearance is provided for the pivot, particularly if bushing 124 is made of steel although it is also possi ble to use another metal such as brass. That part of shaft 122 adjacent to the end of bushing 124 can have a narrowed or pinched portion 126 to maintain preassembly 120 in the hinge as will now be explained.

FIG. 18 illustrates schematically the two-step casting process utilizing the pre-assembly 120. The same reference numerals are used in FIG. 18 as in FIG. to designate the same parts of the die since the introduction of the molten material and movement for the two-step process is the same. In using the die 100 shown in FIG. 18 the preassembly 120 is inserted or located in the upper depression as shown. The molten material is then introduced in gate 104 and flows into branches 106, I08 and 110 as explained above in connection with FIG. 15. The molten material forms a hinge body 130 which includes a pre-assembly 120, and the material of hinge 130 part of which solidifies in pinched portions 126 to maintain pre-assembly 120 in position. Simultaneously with the formation of hinge body 130 molten material flowing through branch forms a hinge tab 132. It will be understood that a previously formed hinge body has moved down to the second depression where it is indicated as 130, and hinge tab 132 is connected to hinge body 130 by being formed around bushing 124. It will be appreciated that hinge tab 132 differs from hinge tab 42 of the previous embodiment in the formation of the pivot portion, but the remainder of hinge tab 132 is formed with the same shape so as to comprise a first part and a second part as explained in the first embodiment of the present invention. Since the pre-assembly 120 has pivotal play or action predetermined by the relationship of shaft 122 and bushing 124, there is no need for the staking step as explained above in the first embodiment, and as mentioned previously, better wear characteristics are provided with the pre-assembled metal pivot.

FIG. 17 illustrates a further embodiment of the present invention using a pre-assembly which includes a steel pin or shaft 142 that is the same as shaft 122 and includes a similar narrowed or pinched section 144. Pre-assembly 140 differs from pre-assembly 120 in that it includes a bushing 146 that is formed from a thermoplastic material such as nylon. The forming of a hinge with pre-assembled insert 140 would be effected in exactly the same manner as shown in FIG. 18 with the pre-assembled insert 120. The difference is that the use of the nylon bushing or sleeve 146 changes the play or pivot action as compared with bushing 124. As the zinc alloy of the hinge tab shrinks around the nylon sleeve during the second step of the casting, this shrinkage exerts a pressure or torque on the sheet shaft 142 that changes the pivot characteristics. The amount of friction torque applied is controlled by the thickness of nylon sleeve 146, and the use of the pre-assembly 140 provides improved wear characteristics, quiet pivot action and self-lubrication as well as the desired pressure torque to minimize the pivot play when desired in certain installations. Again, as in connection with the FIG. 16 embodiment, there would be no use of the staking step when forming the hinge using the pre-assembly 140.

FIGS. 192I illustratean additional embodiment for providing improved wear characteristics for the pivot. In FIG. 19 a hinge body 150 includes side flanges 152 that are substantially the same as the flanges 56 of the first embodiment. Barrel sections 154 are provided, and these are substantially the same as barrel sections 62 of the first embodiment. However, the formation of the pivot projections is provided by special caps that are inserted into the die 100 in the upper mold prior to the introduction of the molten material. The die 100 shown in FIG. 21 with its transfer rod 102 and gates 104, 106, 108 and 110 functions in the same manner as in FIG. 15 so that similar reference numerals have been utilized. Caps 160 are formed of metal to provide the improved wear characteristics, and brass is preferred when the hinge body. and hinge tab are formed of a zinc alloy. As shown in FIG. 20, cap 160 is a preformed insert in the shape of a truncated cone 162 that is provided as a shell having a hollow tapered portion 163. The cap 163 thereby forms a projection having substantially the same shape as projections 112 of the first embodiment. Caps 160 include an outer base flange 164 to assist in location and forming.

The two-step process shown in FIG. 21 is substantially the same as the process shown in FIG. except that the caps 160 are injected into the upper mold before the molten material is injected through gate 104. A hinge body 170 is then formed with part of the material forced into hollow portion 163. At the same time the molten material flowing through branch gate 110 forms a hinge tab 172. It is understood that a previously formed hinge body had been moved down to the lower mold where it is designated by the reference numeral 170 in solidified condition so that hinge tab 172 is thereby formed around caps 160. If the molten material is a zinc alloy, the caps 160 may be brass, and the pivot action and wear will be improved by the zinc alloy pivoting on the brass. The brass cap 160 may also be impregnated with graphite or other lubricant to further improve the pivot action. After the hinge is formed in the second mold by the second step of the process, the I gates are then removed in a conventional manner, and the hinge would then be plated, lacquered and lubricated, with such lubrication preferably effected by drpping the finished hinge in oil. The desired clearance between the pivot surfaces after plating and application of lacquer is kept within 0.002 to 0.003 of an inch. For many applications the use of the zinc alloy for the pivot surfaces is sufficient, such as in cabinet doors or other doors in housing. For such use the final desired clearance can be achieved with the staking step described previously. Where a heavy duty application is involved such as a dwelling door, a pre-assembled insert is used as shown in FIGS. 16 and 17, and a further improved wear pivot can be provided by the use of caps as shown in FIGS. 19 and 20. When the pre-assembly is utilized as shown in FIGS. 16 and 17, it may be pre-lubricated with high temperature lubricants, such as graphite or molybdenum disulphide The above discussion has illustrated different embodiments for providing the novel hinge of the present invention. As explained above, improved pivot and wear characteristics can be achieved, and it is to be em phasized that in the closed position as shown in FIGS. 1 and 4, all fastening means arehidden from view. Accordingly, if the door or handle pull involved is provided with a lock, complete security is achieved since the hinges cannot be removed without unlocking the door.

A further advantage of the present invention is the provision of the continuous or flush outer surface of the hinge body. Since there are no fastening means or other elements interrupting the outer surface, it is possible to provide a continuous design on the surface as shown in FIG. 22, described hereinafter.

It is clear from the previous discussions and in the drawings in the open position of the hinge, the hinge body and hinge tab extend in opposite directions (see FIG. 5). However, in the closed position a continuous surface, such as surface 44 of FIG. 4, is provided by the fitting of surface 72 into opening 70, and this lends itself to the forming of a design thereon. This is shown in FIGS. 22 and 23 where a hinge 180 includes a hinge body 182 on which a decorative design is formed and a hinge tab 184 which has the same general formation as hinge tab 42 in FIG. 5. Hinge tab 184 includes a surface 186 corresponding to surface 72 in FIG. 4 so that surface 186 is continuous with the outer surface of hinge body 182 in the closed position. Surface 186 includes part of a design that matches and corresponds with the design formed on hinge body 182 so that in the closed position, a continuous design is provided. The design shown in FIGS. 22 and 23 is merely illustrative, and many variations in shape of the hinge body and the design applied thereon are contemplated within the scope of the present invention. However, the hinge tab of the invention has generally the same shape in every embodiment except for variation with respect to the pivot surfaces and the particular matching design cast into the area shown as surface 186 in FIG. 22. In the open position of the hinge shown in FIG. 23, the surface 186 having part of the design is still visible.

Since the hinge of the present invention with the flush continuous surface on the external part of the hinge body lends itself to a decorative design, it is contemplated that the hinge and the knob or pull for a door could have matching designs so as to be formed and sold as a set to be applied to the door.

It is generally contemplated that the hinge of the present invention would be utilized for a wooden door. and wood screws would be used for the fastening means. However, with appropriate modification of the size of the elements herein, the novel hinge could be utilized on a metal door with the use of bolts for the fas tening means.

A further possibility would be to form the hinge from thermoplastic material, and a pre-assembled insert such as shown in FIG. 16 could be used for the pivot surfaces.

It is a further feature of the present invention that a novel method of forming the hinge is provided with respect to the inserts illustrated in FIGS. 16-21. The prior art illustrates a two-step casting process for forming pivoting elements. However, a novel combination of steps is provided by the pre-assembled inserts as,

shown in FIGS. 16 and 17 or the pre-formed caps shown in FIGS. 19 and 20 which .are placed in the die,

before the first step of forming the hinge body.

The novel hinge of the present invention is installed by first mounting the hinge tab on the base portion, such as cabinet 34 shown in FIGS. 13. Hinge tab 42 would be fastened, such as by wood screws closely adjacent the edge of the open area containing shelves 38 as shown in FIGS. 2 and 3. The hinge in the open position then has the swinging element,-such as the edge of door 32 placed against edges 54 of flanges 56 and holes are drilled through the door to receive screws that would be threaded into tapped portions 50.

It will be understood that further changes and modifications may be made by those skilled in the art in the particular features of the article and method described hereinabove without departing from the scope of the invention as defined by the following claims.

What is claimed is:

1. In a hinge of the type including a hinge body adapted to be connected to a first element, a hinge tab adapted to be connected to a second element, and pivot means between said hinge body and binge tab to permit swinging of said first and second elements relative to each other between opened and closed positions; the improvement wherein said hinge body has a first substantially flat surface adapted to face away from said first element, a second surface opposite said first surface and adapted to face towards saidfirst element, and a cut out notched section in one end portion adapted to face away from said second .element and a fourth surface opposite said third surface and adapted to face toward said second element, said third surface having a shape substantially the same as said cut out section, first pivot means in said hinge body on opposite sides of said cut out section, said hinge tab having second pivot means positioned to engage said first pivot means to allow said hinge body to swing relative to said hinge tab, with said third surface being substantially flush with said first surface and substantially filling said cut out section in the closed position of said elements, said second surface including first means for fastening said hinge body to said first element whereby said first surface has a continuous surface that is, absent of fastening means, said hinge tab further comprising a pair of legs on said fourth surface that extend beyond alignment with said third surface, said pair of legs extending from said hinge tab in directions parallel to the pivot axis formed by said first and second pivot means and being spaced from said end portion of said hinge body a further distance than said first and second pivot means, said legs extending a distance less than the overlying portion of said first surface in said closed position, second means for fastening said legs to said second element, whereby said legs and said second fastening means are aligned with and covered by said first surface in said closed position, flange means on said hinge body extending from the edges of said first surface substantially into alignment with said fourth surface in said closed position, thereby hiding said legs from view'in said closed position.

2. A hinge according to claim 1 in which saidhinge body one end portion is formed as a pair of spaced barrel sections located on either side of said cut-out section, said hinge tab includes a portion of corresponding barrel shape that is fitted in pivotal relation between said pair of spaced barrel sections, and said hinge tab includes an inclined surface extending between said legs and said third surface, said inclined surface being hidden from view when said hinge is in said closed position 3. A hinge according to claim 2 in which a pair of matching end flanges are formed respectively on the outer ends of said hinge body barrel sections, said flanges extending partway along the outer edges of said hinge body second surface and substantially to alignment with said'fourth surface in said closed position.

4. A hinge according to claim 3 in which the extension of said flanges terminates in an edge located between the inner edge of said cut-out section and said first fastening means, said terminating edge adapted to abut one edge of the one element.

5. A hinge according to claim 2 in which said hinge body barrel sections each include an inward projection to form said first pivot means, said projections being spaced opposite and extending toward each other.

6. A hinge according to claim 5 in which said hinge tab barrel portion includes a pair of depressions, one on each side corresponding in size and adapted to respectively receive a projection for pivoting movement.

7. A hinge according to claim 6 in which said projections and depressions have the shape of truncated cones tapering toward each other at an angle of 30 degrees.

8. A hinge according to claim I in which pivot loosening means are formed in said hinge body, said loosening means comprising at least one groove extending from the inner edge of said notched section.

9. A hinge according to claim 8 in which said loosening means comprises a pair of spaced grooves extending partway along the inner side of said hinge body.

10. A hinge according to claim 2 in which said first pivot means comprises a shaft attached at its ends to said barrel sections respectively, said second pivot means comprises a bushing rotatably mounted on said shaft, and said bushing is attached to said hinge tab.

11. A hinge according to claim 2 in which said hinge body and tab are formed of Zinc 12. The hinge according to claim 1 wherein said second means for fastening comprises a pair of openings formed respectively in said legs to receive screws to effeet the fastening to said second element.

13. In the hinge of the type including a hinge body adapted to be connected to a first element, a hinge tab adapted to be connected to a second element, and pivot means between said hinge body and hinge tab to permit swinging of said first and second elements relative to each other between open and closed positions; the improvement wherein said hinge body comprises a unitarymember having a substantially flat portion, a cut-out notched portion centrally disposed at one end of said flat portion, barrel shaped sections extending from one side of said flat portion in alignment with said one end of said flat portion, whereby said barrel shaped sections are separated by said cut-out notched portion, first pivot means on said barrel shaped sections on opposite sides of said cut-out notched portion, and flange means extending from said one side of said flat portion in alignment with said cut-out notched portions .and wherein said hingetab comprises a unitary member having a first substantially flat surface of -a shape substantially the same as said cut-out notched portion, second pivot means engaging said first pivot means to allow said hinge body to swing relative to said hinge tab, with said first substantially flat surface being substantially flush with the other side of said substantially flatportion of said hinge body and substantially filling said notched portion in said closed position, and leg means extending beyond alignment with said first substantially flat surface between and aligned with said flange means in said closed position and being spaced from said other side of said substantially flat portion a further distance than said first and second pivot means, said leg means extending parallel to the hinge axis formed by said first and second pivot means, said leg means having'a length less than the overlying flat portion in said closed position, whereby said leg means are hidden from view by said flat portion and flange means in said closed position, means for affixing said leg means to said second element, and means on said one' side of said flat portion for affixing said hinge body to said firstelement, whereby said means for fastening and means for affixing are hidden from view in said closed position and said other side of said substantially flat portion is absent of fastening means, said hinge tab further having an inclined surface extending between said leg means on the side thereof toward the other end of said flat portion, said inclined surface being hidden from view in said closed position of said hinge. 

1. In a hinge of the type including a hinge body adapted to be connected to a first element, a hinge tab adapted to be connected to a second element, and pivot means between said hinge body and hinge tab to permit swinging of said first and second elements relative to each other between opened and closed positions; the improvement wherein said hinge body has a first substantially flat surface adapted to face away from said first element, a second surface opposite said first surface and adapted to face towards said first element, and a cut out notched section in one end portion of said hiNge body extending through said first surface, said hinge tab having a third substantially flat surface adapted to face away from said second element and a fourth surface opposite said third surface and adapted to face toward said second element, said third surface having a shape substantially the same as said cut out section, first pivot means in said hinge body on opposite sides of said cut out section, said hinge tab having second pivot means positioned to engage said first pivot means to allow said hinge body to swing relative to said hinge tab, with said third surface being substantially flush with said first surface and substantially filling said cut out section in the closed position of said elements, said second surface including first means for fastening said hinge body to said first element whereby said first surface has a continuous surface that is, absent of fastening means, said hinge tab further comprising a pair of legs on said fourth surface that extend beyond alignment with said third surface, said pair of legs extending from said hinge tab in directions parallel to the pivot axis formed by said first and second pivot means and being spaced from said end portion of said hinge body a further distance than said first and second pivot means, said legs extending a distance less than the overlying portion of said first surface in said closed position, second means for fastening said legs to said second element, whereby said legs and said second fastening means are aligned with and covered by said first surface in said closed position, flange means on said hinge body extending from the edges of said first surface substantially into alignment with said fourth surface in said closed position, thereby hiding said legs from view in said closed position.
 2. A hinge according to claim 1 in which said hinge body one end portion is formed as a pair of spaced barrel sections located on either side of said cut-out section, said hinge tab includes a portion of corresponding barrel shape that is fitted in pivotal relation between said pair of spaced barrel sections, and said hinge tab includes an inclined surface extending between said legs and said third surface, said inclined surface being hidden from view when said hinge is in said closed position.
 3. A hinge according to claim 2 in which a pair of matching end flanges are formed respectively on the outer ends of said hinge body barrel sections, said flanges extending partway along the outer edges of said hinge body second surface and substantially to alignment with said fourth surface in said closed position.
 4. A hinge according to claim 3 in which the extension of said flanges terminates in an edge located between the inner edge of said cut-out section and said first fastening means, said terminating edge adapted to abut one edge of the one element.
 5. A hinge according to claim 2 in which said hinge body barrel sections each include an inward projection to form said first pivot means, said projections being spaced opposite and extending toward each other.
 6. A hinge according to claim 5 in which said hinge tab barrel portion includes a pair of depressions, one on each side corresponding in size and adapted to respectively receive a projection for pivoting movement.
 7. A hinge according to claim 6 in which said projections and depressions have the shape of truncated cones tapering toward each other at an angle of 30 degrees.
 8. A hinge according to claim 1 in which pivot loosening means are formed in said hinge body, said loosening means comprising at least one groove extending from the inner edge of said notched section.
 9. A hinge according to claim 8 in which said loosening means comprises a pair of spaced grooves extending partway along the inner side of said hinge body.
 10. A hinge according to claim 2 in which said first pivot means comprises a shaft attached at its ends to said barrel sections respectively, said second pivot means comprises a bushing rotatably mountEd on said shaft, and said bushing is attached to said hinge tab.
 11. A hinge according to claim 2 in which said hinge body and tab are formed of zinc.
 12. The hinge according to claim 1 wherein said second means for fastening comprises a pair of openings formed respectively in said legs to receive screws to effect the fastening to said second element.
 13. In the hinge of the type including a hinge body adapted to be connected to a first element, a hinge tab adapted to be connected to a second element, and pivot means between said hinge body and hinge tab to permit swinging of said first and second elements relative to each other between open and closed positions; the improvement wherein said hinge body comprises a unitary member having a substantially flat portion, a cut-out notched portion centrally disposed at one end of said flat portion, barrel shaped sections extending from one side of said flat portion in alignment with said one end of said flat portion, whereby said barrel shaped sections are separated by said cut-out notched portion, first pivot means on said barrel shaped sections on opposite sides of said cut-out notched portion, and flange means extending from said one side of said flat portion in alignment with said cut-out notched portions and wherein said hinge tab comprises a unitary member having a first substantially flat surface of a shape substantially the same as said cut-out notched portion, second pivot means engaging said first pivot means to allow said hinge body to swing relative to said hinge tab, with said first substantially flat surface being substantially flush with the other side of said substantially flat portion of said hinge body and substantially filling said notched portion in said closed position, and leg means extending beyond alignment with said first substantially flat surface between and aligned with said flange means in said closed position and being spaced from said other side of said substantially flat portion a further distance than said first and second pivot means, said leg means extending parallel to the hinge axis formed by said first and second pivot means, said leg means having a length less than the overlying flat portion in said closed position, whereby said leg means are hidden from view by said flat portion and flange means in said closed position, means for affixing said leg means to said second element, and means on said one side of said flat portion for affixing said hinge body to said first element, whereby said means for fastening and means for affixing are hidden from view in said closed position and said other side of said substantially flat portion is absent of fastening means, said hinge tab further having an inclined surface extending between said leg means on the side thereof toward the other end of said flat portion, said inclined surface being hidden from view in said closed position of said hinge. 